Process of forming sound-records and other objects.



JONAS W. AYLSWORTH, OF EAST ORANGE; AND EDWARD L. AIKEN, OF ORANGE, NEW JERSEY, ASSIGNOBS TO NEW JERSEY PATENT COMPANY, OF WEST ORANGE, NEW JERSEY, A CORPORATION OF NEW- JERSEY. v

PROCESS OF FORMING SOUND-RECORDS AND OTHER OBJECTS.

No Drawing.

New Jersey, and EDWARD L. AIKEN, a citi zen of the United States, and a resident of Orange, Essex county, New Jersey, have invented a certain new and useful Processof Forming Sound-Records and other Objects, of which the following is a descrip tion.

Our invention relates to a process of forming molded objects, especially fiat plates, such as disk sound records, and also as an article of manufacture, to the disk sound record and other molded objects formed by our improved process. The said objects are claimed in adivisional application Serial No. 861,038, filed September 10, 1914.

Our. invention,.as to certain aspects thereof, is animprovement upon the invention disclosed in application of Jonas W. Aylsworth, Serial No. 543,236, entitled Sound records and process for making the same,

filed February 11, 1910.

By our improved process, molded objects are formed of. refractory condensation products of phenol or equivalent substances, and formaldehyde or other material containing the methylene radical CH The object of our invention is the production of an eflicient, thoroughly practical commercial process of the character .de scribed, in which the desired results may be attained quickly, surely, and with the least possible expense. I

Our object is also to produce as an article of manufacture various molded objects such as disk sound records, formed by our. improved process, and having certain distinguishing characteristics which will hereafter be more fully pointed out.

Our process consists generally in the formation of-a body. or backing having a large proportion of an inert filling material incorporated therein, the formation of a surfacing layer, having a less proportion of filler or no filler, securing or forming the surfacing layer upon .the body, molding the object from the blank thus formed, while at the same time causing the reaction toensue between the ingredients of the object or of the surface layer thereof by application Specification of ietters Patent.

Patented Feb-1,1916.

Application filed August a, 1910. Serial a. 575,981.

of sufficient heat to form a final infusible and insoluble condensation product.

p In carrying out our p ocess', we prefer to proceed as follows :A usible soluble phenolic condensation product or phenol resin is formed. This is preferably the product formed by the reaction of substantially three parts of phenol to two parts of formaldehyde by molecular weights, the reaction apparently taking place according to as explained in the said application of Ayls worth, Serial No. 543,236, and also in applic"ations of Aylsworth, Serial No. 496,060,-

filed May 14, 1909, entitled Plastic compositlon and process of manufacturing the same,

and Serial No. 543,238, filed February 11,

1910, entitled Phenolic condensation product and method of preparing the same. Whether or not the reaction takes place according to the equation given, the resulting condensation product is fusible'and soluble in alcohol and other solvents and is a solid at normal temperatures. Apparently, this product contains, no free formaldehyde or other free (are. active methylene-containing substance, and it is permanently fusible in the sense that it cannot be transformed into an infusible final condensation product by any amuont of heating with or without pressure Without the addition of formaldehyde,

paraformaldehyde, hexa methylene tetraamin, or other hardening agent, but upon I being heated together with a sufiicient quantity, as 10%, of such hardening agent, a

transformation takes place changing the' phenol resin into a final infusible insoluble condensation product, as is explained in the applications of Aylsworth above referred to. To make the blank or body of a disk sound record or ,other object to be molded, We prefer, to dissolve the fusible condensation product or phenol resin. obtained as above described in a liquidsolvent for the same, preferably alcohol. A sufiicient percentage of a methylene-containing or hardening agent is then dissolved in the solvent containing the phenol resin. We {prefer to make use of hexa-methylene-tetra-amin in the proportion of about 10 per cent. of the phenol resin, and this is preferably first dis-- solved in a sufficient amount of water and added to the solution of the phenol resin in the alcohol, since the hexa-methylene-tetraamin dissolvesmore readily in water'than in alcohol. Next, an inert filling body'such as dry wood pulp or other filling materials, such as are described in the applications of Aylsworth above referred to, are placed in a mixing machine,.and'if desired, a coloring material, such as lamp black, is added to the mixture. The solution of the phenol'resin and the hardening agent is then poured into the mixing machine upon. the filler and the components are thoroughly mixed together.

The solvent is then removed as by evaporation, the alcohol preferably being recovered and used over and over. The dried mixture resulting is thenground to uniformity and molded preferably in a hydraulic press with a suitable amount of heat, preferably about 300 degrees F., steam heat, the blank or body thus being formed. -In this molding operation, the hardening reaction between the phenol resin and the hexa-methylene-tetraamin may take lace to a limited extent, although it is on y necessary that the materials be sufiicientlyheated to. coalesce in the mold to form theb'lank Thefilling" body. may be used with "good results in the proportionof two or three to one by weight to the phenol resin.

The surface layer for the object to be molded is preferably formed as follows :-;A.

Preferably, a percentage of the blank mixture itself is used for incorporation with the other ingredients to provide the filling body. We have obtained good results with the following proportions:

Phenol resin 100 parts.

, Blank mixture 10 to 40 parts. Mono-chloro-naphthalene 15 to 30 parts. Hexa-methylene-tetra-amin 10 to 12 parts.

Preferably, the hexa-methylene-tetra-amin in perfectly dry condition is first ground through a paint'mill' together with the chlorinated naphthalene, which is rendered liquid if necessary by heat. This operation results in the formation of a paste. The phenol resinis then ground and the desired amount of the blank'mixture stirred into the same after the grinding, together withthe paste containing the hexa-methylene-tetraamin and the chlorinated naphthalene. A damp powder results. The mixture thus formed is preferably 'now subjected to a more uniform mixing operation by running the same between heated mixing rolls. The mixture is. then preferably formed into sheets by passing the same through heated calender rolls, the heat of the rolls being, sufficient to cause theformation of the sheet, but not to cause the reaction between the ingredients. The surface layer in the form of sheets is then fixed to the blank in any suitable manner. In the case of a plate to be molded, such as a disk sound record, the heated blank together with a surfacing sheet is passed between warm rolls. In the case of a disk sound record which itis desired to mold upon both sides, a surface layer is secured to each side of the blank by passing the heated blank with surfacing sheets on both sides of the same through the rolls. The blank is now ready to be molded and is placed in a suitable mold, heated sufficiently, and pressed preferably in a hydraulic press, the reaction ensuing between the ingredients of the composition while in the press to harden the molded object into a final infusible and insoluble product, such as is described in ap lication of Aylsworth. Serial No. 543,236, a ove referred to, the body and the surface layer being one homogeneous mass. Upon cooling, the-finished molded object may be removed from the mold.

We prefer to use hexa-methylene-tetraamin as a hardening agent for reasons given in applications "of Aylsworth, Serial No. 543,236 and 543,238, although para-formaldehyde or other methylene-containing substances may be used. During-the final reaction, there is no evolution of. dissociation gases, and counteracting pressure, accordingly, need not be used to prevent gasslng 1n the composition, pressure bein used only for the purpose-of giving the ob ect the desired form. In the case of various objects, it will not be necessary to perform the entire reaction within the mold during the shaping of the object, which may be transformed into its final infusible and insoluble form subsequently. In the case of various molded objects having exceedingly delicate surfaces, particularly sound records, the best result is attained by performing the final hardening reaction while the object is being pressed in the mold. The filling body used may be a final infusible phenolic hard condensation product ground fine and mixed with the other ingredients, in place of wood pulp or other organic or inorganic fillers. This is mentioned in applications of Aylsworth, Serial No. 543,236, above referred to,

and Serial No. 575,970, filed Aug. 6,1910.

It isobvious that our invention is not limited to the particular details described, but

that the latter may" be modified within the scope of the appended claims without departing from the spirit of the invention. The body of the record or other object formed should upon molding make a homogeneous mass with the surface layer, to obtain the best results, but for some purposes the body may be formed of an inert filler and a 'bindenother than a phenolic condensation product, particularly if the body is ofmaterial having substantially the same coefiicient of expansion as the surface layer which in such case is in the nature of a veneer. applied to the backing.

Having now described our invention, what we'clai'm and desire to protect by v Letters" Patent is as follows: p

1 The process of forming molded objects which consists in dissolving a permanently fusible phenolic condensation product in a I fusible phenolic condensation product in a liquid solvent therefor, mixing therewith an inert filling material, freeing the mass of the solvent, heating the same and molding the same to shape, substantially as described.

3. The process of forming sound record blanks, which consists in dissolving a permanently fusible phenolic condensation product in a liquid solvent therefor, dissolving therein a sufficient quantity of a methylene containing substance to harden the mass upon subsequent bringing of the same to the reaction temperature, mixing therewith an inert filling material, freeing the mass of the solvent, reducing the same to a uniform powder, heating the same, and molding the same to shape, substantially as described.

4. The process of forming molded objects, which consists in making a blank comprising a phenolic condensation product, forming a surface layer comprising a mixture of a permanently fusible phenolic condensation product, and a methylenecontaining substance in suflicient quantity to harden the mass to an infusible product upon heat treatment, then applying the same to the surface of the blank, and'then applying the object thus made to a suitable mold and molding the same with application of heat, substantially as described.

5. The process of forming molded objects, which consists in making a blank comprising an inert. filling body and a binding agent, forming a surface layer comprising a mixture of a permanently fusible phenolic condensation product and a methylene containing substance insufficient quantity to harden the mass to an infusible product upon heat treatment, then applying the same to the surface of the blank, and then applying the object thus made to a suitable mold and molding the same with application of heat, substantially as described.

6. The process of forming molded objects, which consists in mixing together a perma: nently fusible phenolic condensation product, an inert filler, and a hardening agent, consolidating the ingredients to form a blank, forming a surface layer comprising a mixture of permanently fusible phenolic condensation product .and waahardening,

agent, applying the same. to the surface of,

the blank, then pressing the'object thus formed in a suitable matrix withapplication of heat sufficient to cause the ingredients to react and harden, substantially as described.

7. The process of forming molded objects, which consists in mixing together a permanently fusible phenolic condensation product, an inert filler, and a methylene-containing substance in sufficient quantity to harden the mass to an infusible product upon subsequent heat treatment, -forming a blank thereof, forming a surface layer comprising a mixture of permanently fusible phenolic condensation product and a hardening agent, applying the same to the surface of the blank, and then pressing the object thus formed in a. suitable matrix with application of heat sufficient to cause the ingredients to react and harden, substantially as described.

8. The process-offorming molded objects; which consists in making a blank comprising a phenolic condensation product, forming a surface layer comprising-a mixture of a permanently fusible phenolic condensation product. and a methylene-containing substance in sufficient quantity to harden the mass to an infusible product upon subsequent heat treatment, applying the same to the surface of the blank, and then pressing the object thus formed in a suitable mold with application of heat sufficient to cause the ingredients of the surface layer to react and; harden, substantially as described.

9. The process of forming molded objects, which consists in making a blank comprising aphenolic condensation product, forming a surface layer comprising a mixture of a permanently fusible phenolic condensation product and a methylene-containing substance in sufiicient quantity to harden the mass to an infusible product upon subsequent heat treatment, applying the same to the surface of the blank, and heating theobject thus formed sufiiciently to cause the ingredients of the surface layer to react and harden, substantially as described.

10. The process of forming molded objects, which consists in making a blank comprising an inert filling body and a binding 1 a mixture of a permanently fusible phenolic condensation product and a methylene-containing substance in sufficient quantity to,

harden the mass to an infusible product upon subsequent heat treatment, then applying the same to the surface of the blank, and then pressing the object thus formed in a suitable mold with application of heat sufficient to cause the ingredients of the surface layer to react and harden, substantially as described;

11. The process of forming molded objects, which consists in making a blank comprising an inert filling body and a binding agent, forming a surface layer comprising a mixture. of a permanently fusible phenolic condensation product and a methylene-containing substance in sufficient quantity to harden the mass to an 'infusible product upon subsequent heat treatment, applying the same to the surface of the blank, and heating the object thus formed sufficiently to cause the ingredients of the surface layer to react and harden, substantially as described. I

12. The process of forming molded objects, which consists in making a blank comprising an inert filling body anda binding agent, forming a surface layer comprising a mixture of a permanentlyfusible phenolic condensation product and a methylene-containing substance insufficient quantity to harden and render infusible the mass upon subsequent heat treatment together-with n plasticity agent, applying the same to the surface of the blank, and heating the-ob? ject thus formed sufficiently to, cause the ingredients of "the surface layer to react and harden, substantially as described.

13. The process of forming molded ob-'.

jects, which consists in making a bla'nk'comprising an inert filling body and a binding agent, forming a surface layercomprising.

a mixture of a permanently fusible phenolic condensation product and a methylene-containing substance in sufficient quantity to harden and renderinfusible the mass upon subsequent heat treatment. together with a plasticity agent, and aquantity of an inert filling body, in less proportion than is used in the blank, then applying the same to the surface of the blank, and then pressing the object thus formed in a suitable mold with application of heat sufficient to cause the ingredients of the surface layer to react and harden, substantially as described.

14. The process of forming molded objects, which consists in making a blank comprising an inert filling body and a binding agent, forming a surface layer comprising a mixture of a fusible phenolic condensation product, sufficient hexa-methylene-amin to' harden and render infusible the mass upon subsequent heat treatment, together with chlorinated naphthalene in the proportion of 10% to 40% of the weight of the said fusible.

product, applying the same to the surface 6f the blank, and heating the blank thus formed sufficiently to cause the ingredients of the surface layer to react and harden, substantially as described.

15. The process of forming molded objects, which consists in making a blank comprising an inert filling body and a binding agent, forming a surfacelayer comprising a mixture of a permanently-fusible phenolic condensation product and a methylene-containing substance in sufficient" quantity tohardenand render infusible the mass upon subsequent heat treatment together with a plasticity agent, and a quantityof the composition of said blank in the proportion of less than half of the amount of said fusible product, 1) weight, then applying the same to the sur ace of the blank, and then pressing the blank thus formed in a suitable mold with application of heat'sufiicient to cause the ingredients of the surface layer to reactand harden, substantially as described.

16. The process of forming molded objects, which consists 'in making a blank comprising an inert filling body, a permanently fusible henolic condensationproduct, and a methy ene ating agent therefor, forming a surface layer thereon comprising a mixture of the said blank mixture with a greater quantity of the fusible phenolic condensation product, a; methyleneating a cut and a plasticity agent, and heating su ciently to cause the ingredients to react and the object be transformed into hard infusible product,

substantially as described.

17. The process of forming molded objectspcon'sisting in molding a blank comprising an inert filling body-and a binding agent, forming a surface layer thereon comprising a permanently fusible phenolic-condensation product and a methylene-containing'substance and pressing in a mold while applying heatsufliclentto cause the ingredients of the surface to react and form a hard infusible product,substantially as described.

18. The process of forming molded objects consisting in molding a blank comprising an inert. filling body and a binding agent, forming a surface'layer thereon comprising a permanently fusible phenolic condensation product and a methylene-containing substance and a lasticity agent, and pressing in a mold wh' e applying heat sufficient to cause the ingredients of the surface to react and form a hard fusible product,

substantially as described.

19. The process of forming fiat plates consisting in forming a surfacing material comprising a. fusible phenolic condensation product and a' methylene containing substance, applying the same to a backing plate by passing the late and a sufficient quantity of the material through hot rolls, and heat- I ing the plate .thus formed sulficiently to cause the ingredients of the surface to react to form a hard infusible product,.substantially as described.

20. The process of forming flat plates, consisting in forming a surfacing material comprising a fusible phenolic condensation product and a methylene-containing. substance, forming a thin sheet of the same, and applying to a backing plate by passing the plate and sheet together through heated rolls, substantially as described. Y

, 21. The process of forming molded objects, which consistsin making a blank comprising an inert filling body and a binding agent, forming a surface layer comprising a mixture of a permanently fusible phenolic condensation product, a methylene containing substance in suificient quantity to harden the mass to an infusible product upon heat treatment, and a'plasticity agent, applying the surface layer to the surface of 'the blank, and then molding the blank with application of heat in a suitable matrix, substantially as described.

22. The process of forming molded objects which consists in d'issolvinga permanently fusible phenolic condensation product in a liquid solvent therefor, mixing wood pulp therewith, freeing the mass of the solvent, reducing the same to uniform powder, heating the same, and molding the same to shape, substantially as described.

23. The process of forming moldedfob- V jects which consists in dissolving a permanently fusible phenolic condensation, prodnot in a liquid solvent therefor, mixing wood pulp therewith, freeing the of t jh L: Y Vent heating he same, and molding the.

same to shape, substantially as described.

24. The process of formmg' sound record blanks, which consists in dissolving a permanently fusiblel phenolic condensation product in a liquid solvent therefor, dis-f solving therein a" suflicient quantity of a methylene containing substance to harden the mass uponsubsequent bringing of the same to. the reaction temperature, mixing wood pulp therewith, freeing the massof the solvent, reducing the same to a uniform powder, heating the same, and molding the same to shape, substantially as described.

25. The process of forming molded ob- I jects, whichconsists in mixing together a 65 permanently fusible phenolic condensation product and an agent capable of reacting" 1 chemically-with said condensation product to form an infus'ible phenolic condensation product, consolidating the said ingredients 5 formed a thermo-p astic surface layer, and i to form a blank, ap lying to theblank thus transforming-said blank with application of heat into said infusible product, substan- H This specification signed and witnessed this th day of July, 1910. v 4 JONAS W. AYLSWORTH. Witnesses: Dm SMITH.

1 Demos Holman. Y

EDWARD L. AIKEN.

tially as described.

Witnesses Dm M "FRANK 

